WO2022235728A1 - Metal heater assembly with embedded resistive heaters - Google Patents
Metal heater assembly with embedded resistive heaters Download PDFInfo
- Publication number
- WO2022235728A1 WO2022235728A1 PCT/US2022/027576 US2022027576W WO2022235728A1 WO 2022235728 A1 WO2022235728 A1 WO 2022235728A1 US 2022027576 W US2022027576 W US 2022027576W WO 2022235728 A1 WO2022235728 A1 WO 2022235728A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- metal
- heater
- groove
- resistive
- fill
- Prior art date
Links
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 194
- 239000002184 metal Substances 0.000 title claims abstract description 194
- 239000000758 substrate Substances 0.000 claims abstract description 72
- 238000000034 method Methods 0.000 claims abstract description 25
- 229910052738 indium Inorganic materials 0.000 claims abstract description 13
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 claims abstract description 13
- 230000008018 melting Effects 0.000 claims abstract description 12
- 238000002844 melting Methods 0.000 claims abstract description 12
- 239000007788 liquid Substances 0.000 claims description 26
- 238000010438 heat treatment Methods 0.000 claims description 16
- 239000007787 solid Substances 0.000 claims description 7
- 125000006850 spacer group Chemical group 0.000 claims description 5
- 230000008859 change Effects 0.000 claims description 4
- 239000011888 foil Substances 0.000 claims description 3
- 229910001092 metal group alloy Inorganic materials 0.000 claims description 3
- 238000005219 brazing Methods 0.000 claims description 2
- 238000001816 cooling Methods 0.000 claims description 2
- 238000003466 welding Methods 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 5
- 238000012546 transfer Methods 0.000 description 8
- 238000007711 solidification Methods 0.000 description 7
- 230000008023 solidification Effects 0.000 description 7
- 239000000463 material Substances 0.000 description 5
- 239000000919 ceramic Substances 0.000 description 4
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 4
- 239000000395 magnesium oxide Substances 0.000 description 4
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 4
- 230000008569 process Effects 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 238000000429 assembly Methods 0.000 description 2
- 230000000712 assembly Effects 0.000 description 2
- 238000000231 atomic layer deposition Methods 0.000 description 2
- 238000005229 chemical vapour deposition Methods 0.000 description 2
- 238000000227 grinding Methods 0.000 description 2
- 238000005240 physical vapour deposition Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 239000004065 semiconductor Substances 0.000 description 2
- 239000010409 thin film Substances 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- WYTGDNHDOZPMIW-RCBQFDQVSA-N alstonine Natural products C1=CC2=C3C=CC=CC3=NC2=C2N1C[C@H]1[C@H](C)OC=C(C(=O)OC)[C@H]1C2 WYTGDNHDOZPMIW-RCBQFDQVSA-N 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000011038 discontinuous diafiltration by volume reduction Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000010408 film Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- NJPPVKZQTLUDBO-UHFFFAOYSA-N novaluron Chemical compound C1=C(Cl)C(OC(F)(F)C(OC(F)(F)F)F)=CC=C1NC(=O)NC(=O)C1=C(F)C=CC=C1F NJPPVKZQTLUDBO-UHFFFAOYSA-N 0.000 description 1
- 238000004382 potting Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
- H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
- H05B3/24—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor being self-supporting
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/10—Heater elements characterised by the composition or nature of the materials or by the arrangement of the conductor
- H05B3/12—Heater elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B1/00—Details of electric heating devices
- H05B1/02—Automatic switching arrangements specially adapted to apparatus ; Control of heating devices
- H05B1/0227—Applications
- H05B1/023—Industrial applications
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/02—Details
- H05B3/06—Heater elements structurally combined with coupling elements or holders
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/40—Heating elements having the shape of rods or tubes
- H05B3/54—Heating elements having the shape of rods or tubes flexible
- H05B3/56—Heating cables
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/013—Heaters using resistive films or coatings
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/014—Heaters using resistive wires or cables not provided for in H05B3/54
Definitions
- the present disclosure relates to metal heaters having heating elements embedded therein.
- Metal heaters are used in a variety of applications to provide heat to a target and/or environment via resistive heating.
- One such resistive heater is a cartridge heater, which generally includes a resistive wire heating element wound around a ceramic core.
- the ceramic core defines two longitudinal bores with power and terminal pins disposed therein. A first end of the resistive wire is electrically connected to one power pin and the other end of the resistive wire is electrically connected to the other power pin.
- the ceramic core assembly is disposed within a tubular metal sheath having an open end and a closed end, or, under some assemblies, two open ends, thus forming an annular space between the sheath and the resistive wire/core assembly.
- An insulative material such as magnesium oxide (MgO) or the like, is poured into the open end of the sheath to fill the annular space between the resistive wire and the inner surface of the sheath.
- MgO magnesium oxide
- the open end(s) of the sheath is sealed, for example with a potting compound and/or discrete sealing members.
- the sheath assembly may then be compacted or compressed, such as with swaging or by other suitable processes, to reduce the diameter of the sheath and compact and compress the MgO and at least partially crush the ceramic core, which collapses the core about the pins to ensure good electrical contact and thermal transfer.
- the compacted MgO provides a relatively adequate heat transfer path between the resistive wire heating element and the sheath and it also electrically insulates the sheath from the resistive wire heating element. In this manner, heat generated via the resistive wire heating element is transferred to the body of the metal heater, enabling the entire body of the metal heater to operate at a desired temperature.
- Metal heater applications include thin film processing in semiconductor device manufacturing.
- Thin film processes such as chemical vapor deposition (CVD), physical vapor deposition (PVD), and atomic layer deposition (ALD), among others, can use metal heaters to heat the substrate being processed. Very small temperature variations, even fractions of a degree Celsius, can impact such film processing results. It is accordingly important in these applications of metal heaters that the temperature across the body of the metal heater be accurately and repeatedly controlled.
- a metal heater comprises a metal substrate with a groove formed therein, a resistive heater disposed within the groove, and a fill metal disposed over the resistive heater and substantially filling the groove, wherein the fill metal has a lower melting temperature than the metal substrate.
- the resistive heater is selected from the group consisting of layered heaters, cable heaters, tubular heaters, cartridge heaters, and foil heaters;
- the resistive heater is a cartridge heater;
- the resistive heater is a cable heater;
- the substrate is formed of a metal or a metal alloy;
- the fill metal is indium;
- a cover plate is secured to the metal substrate and disposed over the fill metal;
- a plurality of grooves are in the substrate and a corresponding plurality of resistive heaters are disposed within the plurality of grooves;
- the groove defines an arcuate-shaped interior profile;
- a plurality of resistive heaters are disposed within a single groove; at least one spacer is disposed between adjacent resistive heaters of the plurality of resistive heaters; an amount of the fill metal is calculated based on volume change with temperature of the fill metal, a size of the resistive heater, and a size of the groove; at least one additional groove is substantially filled by the fill metal, wherein
- a method for forming a heating element includes forming a groove in a metal substrate, placing a resistive heater into the groove, filling the groove with a molten fill metal, the molten fill metal having a lower melting temperature than the metal substrate, cooling the metal substrate and the molten fill metal such that the groove is filled with solidified fill metal and the resistive heater is embedded within the solidified fill metal, and securing a cover plate to the metal substrate over the solidified fill metal.
- the metal substrate is heated before filling the groove with molten fill metal; the metal substrate and molten fill metal are cooled to room temperature before bonding the cover plate to the metal substrate and over the solidified fill metal; securing the cover plate to the metal substrate comprises brazing or welding the cover plate to the metal substrate; and the molten fill metal is indium.
- a method of operating a heater comprises supplying power to a metal heater, the metal heater comprising a metal substrate with a groove formed therein, a resistive heater disposed within the groove, and a fill metal disposed over the resistive heater and substantially filling the groove, wherein the fill metal has a lower melting temperature than the metal substrate.
- Power to the metal heater is increased such that the resistive heater provides sufficient heat to melt the fill metal, the fill metal transitioning from a solid state to a liquid state during operation of the heater, while the metal substrate remains solid.
- the fill metal is indium.
- FIG. 1 is a top view of a heater assembly constructed in accordance with the teachings of the present disclosure
- FIG. 2 is cross sectional view of section 2-2 in FIG. 1 ;
- FIG. 3A shows a step of forming the heater assembly in FIG. 1 ;
- FIG. 3B shows another step of forming the heater assembly in
- FIG. 1 is a diagrammatic representation of FIG. 1 ;
- FIG. 3C shows still another step of forming the heater assembly in FIG. 1 ;
- FIG. 3D shows still yet another step of forming the heater assembly in FIG. 1 ;
- FIG. 4A is a cross-sectional view of a resistive heater disposed in one form of a rectangular-shaped groove in accordance with the teachings of the present disclosure
- FIG. 4B is a cross-sectional view of a resistive heater disposed in another form of a rectangular-shaped groove
- FIG. 5A is a cross-sectional view of a resistive heater disposed in one form of an angled groove in accordance with the teachings of the present disclosure
- FIG. 5B is a cross-sectional view of a resistive heater disposed in another form of an angled groove
- FIG. 6 is a cross-sectional view of a resistive heater disposed in a trapezoid-shaped groove in accordance with the teachings of the present disclosure
- FIG. 7 A is a cross-sectional view of a resistive heater disposed in one form of an oblong-shaped groove in accordance with the teachings of the present disclosure
- FIG. 7B is a cross-sectional view of a pair of resistive heaters disposed in another form of an oblong-shaped groove
- FIG. 7C is a cross-sectional view of a pair of resistive heaters disposed in yet another form an oblong-shaped groove with a filler insert between the pair of resistive heaters;
- FIG. 8 is a flow chart showing a method of making a heater according to the present disclosure.
- FIG. 9 is a cross-sectional view of another form of a heater assembly constructed in accordance with the teachings of the present disclosure.
- the heater assembly 10 includes a substrate 100 with at least one groove 110 and a cover plate 160 (removed in FIG. 1 for purposes of clarity) secured to the substrate 100 and disposed over the groove 110.
- the groove 110 defines a spiral-shape as shown.
- the groove 110 has a different shape, by way of example, linear, serpentine, and multiple grooves in concentric circles, among others.
- the groove 110 extends from an upper (+z direction) surface 102 towards a lower (-z direction) surface 104 of the substrate 100, and a resistive heater 150 is disposed within the groove 110.
- the resistive heater 150 is positioned at, or near, a bottom (-z direction) of the groove 110.
- the resistive heater 150 may be positioned at any location within the groove 110, and even protruding above the groove 110, while remaining within the scope of the present disclosure.
- a low melting temperature metal or alloy 112 (referred to herein simply as “fill metal 112”) is also disposed within the groove 110 and the resistive heater 150 is disposed or embedded within the fill metal 112.
- the cover plate 160 extends across the upper surface 102 and the groove 110 as shown. In some variations, the cover plate 160 is secured (e.g., welded or brazed) to the substrate 100. However, it should be understood that the cover plate 160 is optional.
- the phrase “melting temperature” as used herein refers the temperature range from which the fill metal 112 begins to transform from a solid to a liquid, and to the temperature at which the metal is completely liquid/molten. Therefore, the melting temperature can be a range of temperatures for the fill metal 112 and is not necessarily limited to a specific, single temperature.
- Non-limiting examples of materials from which the substrate 100 and/or the cover plate 160 are made include steels, stainless steels, and aluminum alloys, among others.
- non-limiting examples of resistive heaters 150 include cable heaters, cartridge heaters, bare wire heating elements, coil heaters, tubular heaters, layered heaters, and foil heaters, among others.
- teachings of the present disclosure include a single resistive heater 150 as well as multiple resistive heaters 150, which may further be arranged in zones and independently controlled. Also, more than one type of resistive heater 150 may be employed in the heater assembly 10 while remaining within the scope of the present disclosure.
- the method 20 includes positioning the resistive heater 150 within the groove 110 as indicated in FIG. 3A.
- the groove 110 may be formed according to methods known in the art, such as cutting with grooving knives, drilling, grinding, milling, and lathing, among others.
- the size (e.g., diameter) of the groove 110 is larger (greater) than a diameter, or outer dimension, of the resistive heater 150.
- the size of the of the groove 110 is at least 100% larger than a diameter of the resistive heater 150.
- the size of the groove 110 is at least 200% larger than a diameter of the resistive heater 150, for example, about 300% larger, about 400% larger, about 500% larger, about 600% larger, about 700% larger, or about 1000% larger than the diameter of the resistive heater 150.
- the method 20 includes pouring liquid fill metal 112a into the groove 110 such that an upper surface 113 of the liquid fill metal 112a is at a desired height (z direction) as shown in FIG. 3C.
- the method 20 also includes securing a cover plate 160 to the substrate 100 as shown in FIG. 3D.
- the substrate 100 with the resistive heater 150 disposed in the groove 110 is heated before pouring the liquid fill metal 112a into the groove 110.
- the substrate 100 with the resistive heater 150 disposed in the groove 110 is heated to a temperature that is generally equal to or greater than a melting temperature of the liquid fill metal 112a.
- the liquid fill metal 112a is liquid indium (T(melt) « 157 °C) and the substrate 100 with the resistive heater 150 disposed in the groove 110 is heated above (i.e., greater than) 157 °C before the liquid indium is poured into the groove 110. Heating of the substrate 100 results in a volume expansion of the substrate 100 and an expansion of the volume (and size) of the groove 110. Accordingly, when the groove 110 filled with the liquid fill metal 112a cools, solidification shrinkage of the liquid fill metal 112a is at least partially accommodated for by the volume shrinkage of the substrate 100.
- the groove 110 is filled with the liquid fill metal 112a such that the upper surface 113 of the liquid fill metal 112a is generally equal in height (z direction) or on the same plane (x-y plane) as the upper surface 102 of the substrate 100. Also, the liquid fill metal 112a solidifies such that the resistive heater 150 is embedded within the fill metal 112. The resistive heater 150 may be completed encased by, or embedded within the fill metal 112, or partially encased by or embedded within the fill metal 112.
- the fill metal 112 functions as an enhanced heat transfer medium compared to physical contact between the resistive heater 150 and the substrate 100.
- a heater assembly with a heating element disposed in a groove of generally the same size can result in gaps/voids (e.g., air gaps) between the heating element and the substrate along a length of the heating element. Also, such gaps result in reduced heat transfer between the heating element and the substrate such that undesirable non-uniform heating of the substrate occurs.
- pouring the liquid fill metal 112a into the groove 110 and onto the resistive heater 150 provides direct and intimate contact between the resistive heater 150 and the fill metal 112, and thus between the fill metal 112 and the substrate 100.
- the fill metal 112 enhances metal-to-metal contact between the resistive heater 150 and the substrate 100 without the presence of gaps. Accordingly, enhanced heat transfer and enhanced heat transfer uniformity is provided by the heater assembly 10 according to the teachings of the present disclosure, which is further described in greater detail below.
- the fill metal 112 include indium (T(melt) « 157 °C), tin (T(melt) « 232 °C), zinc (T(melt) « 420 °C), and alloys thereof, among others.
- the liquid fill metal 112a typically exhibits a volume reduction (shrinkage) during solidification. For example, indium exhibits a solidification shrinkage of about 4 volume percent.
- solidification shrinkage is accounted for during pouring of the liquid fill metal 112a into the groove such that the upper surface 113 of the fill metal 112 is at a desired height (z direction) relative to the upper surface 102 of the substrate 100.
- the solidification shrinkage of the liquid fill metal 112a is accounted for such that the upper surface 113 is generally planar with the upper surface 102 of the substrate 100.
- the solidification shrinkage of the liquid fill metal 112a is accounted for such that the upper surface 113 of the fill metal 112 is below (-z direction) the upper surface 102 of the substrate 100 a predefined distance.
- the solidification shrinkage of the liquid fill metal 112a is accounted for such that the upper surface 113 of the fill metal 112 is above (+z direction) the upper surface 102 of the substrate 100 a predefined distance.
- the upper surfaced 113 can be lowered (-z direction) via grinding such that a planar surface across the upper surface 102 of the substrate and the fill metal 112 is provided.
- FIGS. 2 and 3A-3D show the groove 110 with an arcuate shaped interior profile (e.g., circular- or semi-circular-shaped interior profile), heater assemblies with grooves having interior profiles with other shapes are included in the teachings of the present disclosure.
- FIGS. 4A-4B show examples of rectangular-shaped grooves 110 with the resistive heater 150 positioned at the bottom of, and the fill metal 112 is disposed within, the rectangular-shaped grooves 110.
- angled grooves 110 are shown with the resistive heater 150 positioned at the bottom of, and the fill metal 112 is disposed within, the angled grooves 110.
- a trapezoid-shaped groove 110 is shown with the resistive heater 150 positioned at the bottom of, and the fill metal 112 is disposed within, the trapezoid-shaped grooves 110.
- FIGS. 7A-7C oblong-shaped grooves 110 are shown.
- the resistive heater 150 is positioned at the bottom of, and the fill metal 112 is disposed within, the oblong-shaped groove 110.
- a pair of resistive heaters 150 are positioned at the bottom of the oblong-shaped groove 110 and liquid fill metal 112a is poured into the oblong-shaped groove to form the fill metal 112.
- FIG. 7 A the resistive heater 150 is positioned at the bottom of, and the fill metal 112 is disposed within, the oblong-shaped groove 110.
- a pair of resistive heaters 150 are positioned at the bottom of the oblong-shaped groove 110 and liquid fill metal 112a is poured into the oblong-shaped groove to form the fill metal 112.
- a spacer or insert 115 is placed in the oblong-shaped groove 110 between the pair of resistive heaters 150 and the liquid fill metal 112a is poured into two separate cavities between the insert 115 and the interior surface of the groove 110. Therefore, a plurality of resistive heaters 150 may be placed into a single groove 110, with or without a spacer, or spacers, according to the teachings of the present disclosure. It should also be understood that the resistive heater 150 need not be at the bottom of the groove 110 as illustrated herein, and instead may be held in position at any location within the groove 110 while the liquid fill metal 112a is poured into the groove(s) 110.
- a method 40 for forming a heater includes forming a groove (such as groove 110) in a metal substrate (such as substrate 100) at 410 and placing a resistive heater (such as resistive heater 150) into the groove at 420.
- the metal substrate is heated, for example to greater than or equal to about 157 °C when a fill metal is indium, and at 440 the groove is filled with the molten fill metal.
- the metal substrate and molten fill metal are cooled to room temperature to solidify the molten fill metal.
- a cover plate may afterwards be affixed to the metal substrate (not shown).
- the fill metal may be used to fill an existing groove without a cover plate.
- the groove would be disposed or embedded within the metal substrate, and the end(s) of the groove would be sealed after filling the groove.
- a method of operating the heater assembly 10 includes supplying power to the metal heater 10, increasing the power such that the resistive heater 150 provides sufficient heat to melt the fill metal 112, the fill metal 112 transitioning from a solid state to a liquid state during operation of the heater 10, while the metal substrate 100 remains solid. Therefore, during operation of the heater assembly 10, the fill metal 112 is molten and thus fills in any voids and expands in volume to improve heat transfer from the resistive heater 150 to the metal substrate 100.
- the fill metal 112 need not necessarily completely fill the groove 110 while remaining within the scope of the present disclosure.
- a volume change with temperature can be calculated such that the volume during operation is sufficient to fully encase, or to sufficiently encase for improved heat transfer, the resistive heater 150.
- the volume change with temperature of the fill material 112, the size of the resistive heater 150, and the size of the groove 110 would be taken into account to calculate the amount of fill metal 112 needed to sufficiently encase the resistive heater 150 during operation.
- the size of the groove 110 can be calculated to sufficiently encase the resistive heater 150.
- FIG. 9 another form of a metal heater is illustrated and generally indicated by reference numeral 200.
- a plurality of “layers” of embedded resistive heaters 210 are disposed within grooves 220 of a metal substrate 230 (or plurality of separate substrates that are joined together, not shown).
- the metal heater 200 also includes a fill metal 240 as previously described, which has a lower melting temperature than the metal substrate 230.
- the layers of resistive heaters 210 are arranged in a staggered configuration along the X-axis and are layered along the Z-axis as shown in order to provide improved temperature uniformity.
- resistive heaters 210 and grooves 220 are merely exemplary, and thus any number of layers and locations of resistive heaters 210 and grooves 220 may be implemented while remaining within the scope of the present disclosure.
- the metal heater 200 generally may include any of the features as set forth above, individually or in any combination, while remaining within the scope of the present disclosure.
- cover plates 250 are provided on both the top and bottom of the metal heater 200.
- first, second, third, etc. may be used to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections, should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer and/or section, from another element, component, region, layer and/or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section, could be termed a second element, component, region, layer or section without departing from the teachings of the example forms. Furthermore, an element, component, region, layer or section may be termed a “second” element, component, region, layer or section, without the need for an element, component, region, layer or section termed a “first” element, component, region, layer or section.
- the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2023567902A JP2024516035A (en) | 2021-05-04 | 2022-05-04 | Metallic heater assembly having embedded resistive heater - Patents.com |
DE112022002440.2T DE112022002440T5 (en) | 2021-05-04 | 2022-05-04 | HEATER ARRANGEMENT WITH EMBEDDED RESISTIVE HEATERS |
KR1020237040897A KR20240004673A (en) | 2021-05-04 | 2022-05-04 | Metal heater assembly with resistance heater installed |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US202163183932P | 2021-05-04 | 2021-05-04 | |
US63/183,932 | 2021-05-04 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2022235728A1 true WO2022235728A1 (en) | 2022-11-10 |
Family
ID=81846441
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2022/027576 WO2022235728A1 (en) | 2021-05-04 | 2022-05-04 | Metal heater assembly with embedded resistive heaters |
Country Status (6)
Country | Link |
---|---|
US (1) | US20220361296A1 (en) |
JP (1) | JP2024516035A (en) |
KR (1) | KR20240004673A (en) |
DE (1) | DE112022002440T5 (en) |
TW (1) | TW202245545A (en) |
WO (1) | WO2022235728A1 (en) |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20050101082A1 (en) * | 2003-10-27 | 2005-05-12 | Kyocera Corporation | Composite material, wafer holding member and method for manufacturing the same |
EP1074041B1 (en) * | 1998-03-26 | 2005-10-26 | Applied Materials, Inc. | A high temperature multi-layered alloy heater assembly |
FR3092778A1 (en) * | 2019-02-14 | 2020-08-21 | Thermocoax | "Method of soldering heating elements to produce a heating source, hob, immersion heater or infrared source" |
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2022
- 2022-05-04 US US17/736,185 patent/US20220361296A1/en active Pending
- 2022-05-04 TW TW111116850A patent/TW202245545A/en unknown
- 2022-05-04 JP JP2023567902A patent/JP2024516035A/en active Pending
- 2022-05-04 KR KR1020237040897A patent/KR20240004673A/en unknown
- 2022-05-04 DE DE112022002440.2T patent/DE112022002440T5/en active Pending
- 2022-05-04 WO PCT/US2022/027576 patent/WO2022235728A1/en active Application Filing
Patent Citations (3)
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EP1074041B1 (en) * | 1998-03-26 | 2005-10-26 | Applied Materials, Inc. | A high temperature multi-layered alloy heater assembly |
US20050101082A1 (en) * | 2003-10-27 | 2005-05-12 | Kyocera Corporation | Composite material, wafer holding member and method for manufacturing the same |
FR3092778A1 (en) * | 2019-02-14 | 2020-08-21 | Thermocoax | "Method of soldering heating elements to produce a heating source, hob, immersion heater or infrared source" |
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JP2024516035A (en) | 2024-04-11 |
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DE112022002440T5 (en) | 2024-03-07 |
TW202245545A (en) | 2022-11-16 |
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